Smart shut-off valve for high pressure hose

The present disclosure relates generally to high pressure hoses and, more particularly, to methods and systems for automatically shutting off high pressure hoses.

A variety of industrial applications utilize high pressure fluids. For example, water jet cutting may utilize high pressure water jets to cut materials, and grit blasting may be utilized to roughen and/or smooth surfaces of materials. In both of these example applications, the operator directs a pressurized fluid, potentially carrying solid particles, towards the target surface through a hose. However, such activities have the inherent risk of uncontrolled release of the pressurized fluid from the hose, which may occur if the operator loses grip on the hose, for example, due to the operator losing consciousness or due to operator fatigue. Such uncontrolled release of the pressurized fluid may harm the operator or others surrounding the work area.

To eliminate this risk, existing hoses for such high pressure fluid activities are equipped with safety devices, such as dead-man handle mechanisms. Dead-man handle mechanisms conventionally include a button (or lever) that must be engaged by the operator in order to allow flow from the hose but stops the flow when disengaged. Thus, dead-man handle mechanisms require the operator to continuously apply pressure on the button/handle for prolonged periods, which is generally uncomfortable and may cause muscle strain. As a result, operators often bypass such safety devices, for example, by tying a rope around the button/lever of the dead-man handle mechanisms such that it remains in the engaged position.

Accordingly, methods and systems are desired for ensuring the safety of operators utilizing high pressure hoses and other high pressure equipment.

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an exhaustive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

According to an embodiment consistent with the present disclosure, a valve system for a hose includes a valve operable to open or close a fluid pathway defined in the hose. The valve system also includes a sensor operable to sense a condition, and a controller in communication with to the sensor and operable to determine occurrence of the condition, wherein the controller is programmed to direct the valve to close the fluid pathway upon determining occurrence of the condition.

According to another embodiment, a valve system for a hose includes a base mountable to an exterior surface of the hose and a housing operatively coupled to the base and containing one or more sensors and a controller in communication with the one or more sensors. The valve system also includes a valve mountable to the hose and in communication with the controller, the valve being operable to open or close a fluid pathway of the hose, wherein the one or more sensors are operable to sense a condition of the hose and the controller communicates with the one or more sensors to determine occurrence of the condition, and wherein the controller is programmed to direct the valve to close the fluid pathway upon determining occurrence of the condition.

Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims.

Embodiments of the present disclosure will now be described in detail with reference to the accompanying Figures. Like elements in the various figures may be denoted by like reference numerals for consistency. Further, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Additionally, it will be apparent to one of ordinary skill in the art that the scale of the elements presented in the accompanying Figures may vary without departing from the scope of the present disclosure.

Embodiments in accordance with the present disclosure generally relate to high pressure hoses and, more particularly, to methods and systems controlling use of high pressure hoses. The embodiments disclosed herein include a valve system for a hose. The valve system may include a valve operable to open or close a fluid pathway defined in the hose, a sensor, and a controller configured to direct the valve to close the fluid pathway upon determining occurrence of a predefined condition detected by the sensor. In embodiments, the sensor is at least one of an accelerometer, a gyroscope, and/or a magnetometer, and the valve system further comprises a memory storing instructions that, when executed by the controller, compare data captured by the sensor to a threshold value and cause the valve to close the fluid pathway if the data captured by the sensor exceeds the threshold value.

In embodiments, the sensor is at least one of a temperature sensor and/or a humidity sensor, and the valve system further comprises a memory storing instructions that, when executed by the controller, calculate a heat index value using data captured by the sensor, compare the heat index value to a shutdown threshold value stored in the memory, and cause the valve to close the fluid pathway if the heat index value exceeds threshold value. In such embodiments, a resume operation temperature threshold value may be stored in the memory, and the instructions, when executed by the controller, cause the valve to maintain closure of the fluid pathway until the heat index value calculated by the controller is equal to or less than the resume operation threshold temperature.

In embodiments, the sensor comprises at least a pressure sensor, and the valve system further comprises a memory storing instructions that, when executed by the controller, determine a start time by comparing pressure data captured by the pressure sensor to a threshold pressure value, and cause the valve to close the fluid pathway if the pressure data captured by the pressure sensor exceeds the threshold pressure value for a first predetermined time period. In such embodiments, the instructions, when executed by the controller, may also cause the valve to maintain closure of the fluid pathway for a second predetermined time period.

In embodiments, the valve is a normally closed valve. In such embodiments, the valve system may further include a first power supply for supplying power to the controller and a second power supply for supplying power to the valve, and a relay, wherein the controller is operable to open or close the relay, and the second power source energizes the valve when the relay is closed. Accordingly, the valve system described herein is operable to control use of the hose and ensure that the hose is inoperable if not being under the operator's control or in a dangerous working environment, and ensure that operator is not operating the hose when fatigued.

1 FIG. 100 100 102 102 104 106 100 106 106 102 104 100 102 100 is a schematic side view of an example valve system, according to one or more embodiments of the present disclosure. The valve systemis depicted in conjunction with a hose, where the hoseincludes an outletand defines an interior passagewaythat may be opened or closed via the valve system. When the interior passageway(alternately referred to as “the fluid pathway”) of the hoseis closed, fluid is inhibited from flowing out of the outlet. While the valve systemis depicted when utilized with the hose, the valve systemmay be utilized with other types of conduits without departing from the present disclosure.

100 110 106 102 110 106 104 110 104 110 110 110 104 110 110 110 110 104 110 110 The valve systemincludes a valvethat is operable to open or close the interior passagewayof the hose. Thus, the valvemay be set to a closed position, in which a seal or “occluding” member (not shown) obstructs the interior passagewaysuch that flow out of the outletis inhibited, and the valvemay be set to an at least partially open position, in which the seal member is oriented such that at least some flow out of the outletis permitted. In embodiments, the valveis a solenoid valve. In embodiments, the valveis a normally open valve, meaning that the seal member of the valvedefaults to (or is biased towards) the open position where flow out of the outletis permitted, until the valveis activated (energized), wherein activation (energization) of the valvecauses the seal member to move (transition) to the closed position. In other embodiments, the valveis a normally closed valve, meaning that the seal member of the valvedefaults to (or is biased towards) the closed position where flow out of the outletis inhibited, until the valveis activated (energized) and such activation (energization) of the valvecauses the seal member to move (transition) to the at least partially open position.

100 112 100 100 114 112 114 116 102 114 112 114 102 102 114 114 102 112 114 114 114 114 The valve systemmay also include a housingwithin which at least some of the electronic components of the valve systemare housed. In the illustrated embodiment, the valve systemalso includes a baseupon which the housingis mounted. Here, the baseis provided on (secured to) an exterior surfaceof the hose. In particular, the basemay provide or define a mounting surface on which the housingcan be mounted. The basedefines a bore through which the hoseextends, such that the hoseextends through the baseand the baseextends at least partially about the hose. In embodiments, the housingis removably mounted on the base, for example, the housingmay be magnetically attached to the baseor attached to the basevia mating threads or a mechanical interface (e.g., bolted engagement).

100 118 110 112 118 110 112 118 112 110 102 118 Also in the illustrated embodiment, the valve systemincludes a bridgeextending between the valveand the housing. The bridgedefines an internal passageway through which wiring and/or other electrical components may extend, for example, to operably couple internal components of the valveto the electronic components housed within the housing. In embodiments, the bridgeis a flexible coupling member (i.e., made from a flexible material) that allows for relative movement between the housingand the valvethat may occur due to the flexibility of the hose. In other embodiments, the bridgemay comprise a rigid coupling member.

2 FIG. 1 FIG. 1 FIG. 112 100 100 202 204 202 204 202 110 204 110 106 schematically depicts an example electronic package that may be contained within the housingof the valve systemof, according to one or more embodiments of the present disclosure. As shown, the valve systemincludes at least one sensorand a controller(e.g., a micro processor). The sensor(s)may be operable to sense a condition (e.g., a predefined condition), and the controllermay be electronically (communicably) coupled to the sensorand the valve. The controllermay be configured to direct the valveto close (or open) the interior pathway() upon detection of the condition.

202 204 112 100 112 100 210 204 212 110 214 112 210 212 216 210 210 218 212 210 2 FIG. 1 FIG. The sensorand the controllerare housed or disposed within the housing. However, as shown in, the valve system() may include additional electrical components that are also at least partially housed/disposed within the housing. For example, in the illustrated embodiment, the valve systemfurther includes a first power supplyfor supplying power to the controller, a second power supplyfor supplying power to the valve, and a relayhoused (enclosed or contained) within the housing. In embodiments, the first power supplyand/or the second power supplymay be configured to be turned “on” or “off” as desired, for example, a first switchmay be operably connected to the first power sourcefor switching the first power source“on” or “off” and a second switchmay be operably connected to the second power sourcefor switching the second power source“on” or “off”.

100 220 204 216 218 220 112 102 1 FIG. In addition, the valve systemmay include a reset switchoperably coupled to the controller. As shown in, the first and second switches,and the reset switchmay be supported by the housingand protrude therefrom such that an operator may manually activate them when holding the hoseduring use.

110 212 222 214 222 222 214 222 212 110 222 212 110 110 110 106 102 212 110 106 102 212 214 212 110 110 110 106 102 2 FIG. In the illustrated example, the valveand the second power supplyare connected together via a circuit loop, and the relayis arranged in the circuit loopand operable to open or close the loop. When the relayis deactivated, as depicted in, the circuit loopis open and the second power supplyis not powering the valve. However, when activated, the circuit loopis closed such that the second power supplyis able to supply power to the valve. In this example, the valveis a normally closed valve, such that the valvecloses the interior passagewayof the hosewhen deactivated (i.e., when not receiving power from the second power supply) and such that the valveat least partially opens the interior passagewayof the hosewhen activated (i.e., when receiving power from the second power supply). Thus, activation of the relaycauses the second power supplyto supply power to the valve, which in turn activates the valveand causes the valveto at least partially open the interior passagewayof the hose.

110 212 214 204 214 222 204 212 110 106 102 204 210 202 220 216 210 210 204 210 214 214 212 110 In some embodiments, the valveonly receives power from the second power supplywhen the relayis activated, and the controlleris operable to activate (close) the relayto thereby close the circuit loop. Thus, the controlleris operable to cause the second power supplyto supply power to the valveto thereby open the interior passagewayof the hose. As shown, the controlleris connected to the first power supply, the sensor, and to the reset switch. Activation of the first switchturns on the first power supply, thereby allowing the first power supplyto supply power to the controllerand, once activated (turned on), the first power supplywill continuously send power through the relay, thereby activating the relay, and thereby ensuring that power from the second power supplyreaches the valve.

204 202 204 204 204 214 222 212 110 106 102 214 222 212 110 220 204 According to embodiments of the present disclosure, the controllermay be programmed with an algorithm that detects occurrence of a condition based on data from the sensor(s). If the algorithm embedded within the controllerdetects (determines) occurrence of the condition, the controllermay then be programmed to cut power to the relay, which in turn opens the relayand opens the circuit loopsuch that the second power sourceis unable to supply power to the valve, which will close the passagewayof the hose. To restore power to the relayto thereby close the circuit loopand thereby allow the second power supplyto supply power to the valve, the reset switchmay be activated to return the controllerto its normal operation.

204 224 204 204 202 204 110 106 224 100 100 100 100 224 100 The controllermay include a memorythat may store computer readable instructions, such as one or more algorithms as further described below. The controllermay execute (run) such computer readable instructions and, when executing such instructions, the controllermay utilize data received from the sensor(s)in order to determine occurrence of the condition, and the controllermay direct the valveto close the interior pathwayupon determining occurrence of the condition. The memorymay also store operational data concerning usage of the valve systemand whether the condition occurred, such as the total time the valve systemwas operated during a given time period, the number of breaks/rests taken by the operator during a time period, the ambient temperature encountered during usage of the valve system(including maximum ambient temperature encountered), and whether the valve systemencountered any impacts or safety incidents. By storing such operational data on the memory, operators may later recall such operational data when evaluating usage of the valve systemat a later date/time.

202 204 102 102 100 204 110 106 102 102 202 204 102 100 204 110 106 102 102 202 204 102 100 102 204 110 106 102 102 204 In some embodiments, the condition to be sensed by the sensor(s)and determined by the controllermay be a “fall condition”, for example, where the operator loses control of the hoseand/or where the hosefalls to the ground. Thus, the valve systemmay be equipped with fall detection capabilities, whereby the controllercauses the valveto close the interior passagewayof the hoseupon detecting that the hosehas fallen. In other embodiments, or in addition thereto, the condition to be sensed by the sensorand determined by the controllermay be an “unsafe temperature condition”, for example, where the hoseis being utilized in an environment subject to unsafe operating temperatures. Thus, the valve systemmay be equipped with temperature detection capabilities, whereby the controllercauses the valveto close the interior passagewayof the hoseupon detecting that the hoseis located in an environment exhibiting unsafe operating temperatures. In yet other embodiments, or in addition to detecting a fall condition and/or an unsafe temperature condition, the condition to be sensed by the sensorand determined by the controllermay be a predetermined time interval that the operator may work before they must take a break (i.e., a “time interval condition”), for example, to ensure that the operator is not continuously using the hosefor unsafe periods of time that may result in operator fatigue and to otherwise ensure that the operator is taking breaks at required/recommended intervals. Thus, the valve systemmay be equipped with a timer and pressure detection capabilities to allow for detection of when the hoseis being utilized and for how long, whereby the controllercauses the valveto close the interior passagewayof the hoseupon detecting that the hosehas been continuously operated for a certain period of time (e.g., as mandated by a government agency or law). In embodiments, the controllerincludes the timer.

202 204 214 100 202 202 100 202 202 100 202 202 202 202 202 The sensormay include more than one sensor and/or more than one type of sensing capability, and the type of sensor(s) utilized depends on type of algorithm stored in the controller(e.g., for detecting the fall condition). In addition, the type of sensor(s) utilized may also depend on the metrics of the additional metrics concerning de-energization of the relay. In embodiments where the valve systemis configured to detect a fall condition, the sensormay include at least an accelerometer and, in some embodiments, the sensormay also include a gyroscope and a magnetometer. In embodiments where the valve systemis configured to detect an unsafe temperature condition, the sensorincludes at least a temperature sensor and, in some embodiments, the sensoralso includes a humidity sensor. In embodiments where the valve systemis configured to detect a time interval condition, the sensormay include at least a pressure sensor and a timer. In embodiments where the sensorincludes a plurality of sensors, as described above, one or more of the sensors may be integrated into a single sensor chip or a plurality of sensor chips may be utilized. Regardless of the number and type of sensor(s)utilized, the sensor(s)may be configured to take readings at various frequencies (intervals), for example, the sensormay continuously take readings or take readings every minute, etc.

100 226 226 112 102 226 226 110 106 202 102 102 204 110 204 226 110 202 102 204 110 204 226 110 The valve systemmay also include a display. The displaymay be mounted on the housingsuch that it is visible to the operator holding the hose. In embodiments, the displayis a liquid-crystal display (LCD). The displaymay be utilized by the operator to determine the reason why the valveclosed the interior passageway, and may also help facilitate troubleshooting. For example, if the sensorsenses that the hosehas fallen or that the operator has lost control of the hoseand the controllerhas closed the valvein response thereto, the controllermay cause the displayto indicate that the valveis has been closed because a fall condition has been detected. Alternatively, or in addition thereto, if the sensorsenses that the hoseis being operated in an environment exhibiting unsafe operating temperatures and the controllerhas closed the valvein response thereto, the controllermay cause the displayto indicate that the valvehas been closed because an unsafe temperature condition has been detected.

100 226 112 204 226 204 110 102 226 102 102 102 202 202 204 202 102 204 204 204 110 106 102 204 110 226 204 102 204 110 106 102 204 110 106 In one example, where the valve systemis configured to detect the time interval condition, the displaymay comprise a seven-segment display affixed on top of the housing. Here, the total time period that the operator may work before taking a break may be programmed within the controllerand the displayis operable to show the time remaining (i.e., a countdown) from the total time period until the controllerwill cause the valveto close. For example, prior to beginning use of the hose, the displaymay show “0.0.0.0”, indicating that operation of the hoseis allowed in the present moment. Once the operator begins using the hose, the hosebecomes pressurized, which may be detected by the sensor(s)(e.g., when the sensorincludes a pressure sensor). The controllerutilizes data from the sensorto determine that operation of the hosehas begun and the controllerbegins running an algorithm stored in the controller, during which time the controllercauses the valveto open the interior passagewayof the hose. The controllerruns the algorithm and continues to allow the valveto remain in the open position, during which time the displaywill continue displaying “0.0.0.0”. However, when the controllerdetermines that the hosehas been operated for the predetermined time interval (i.e., a first predetermined time period), the controllercauses the valveto close the interior passagewayas detailed above. This will force the operator to stop using the hose(i.e., such that the operator can take a break/rest). Stated differently, the controllercauses the valveto close the interior passagewayupon determining that the time interval condition has been satisfied.

204 102 204 110 226 110 102 204 110 226 102 204 110 204 110 226 102 Further, once the controllerhas determined that the hosehas been operated for the predetermined time interval, the controllermaintains the valvein the closed position and causes the displayto show an amount of time that the valvewill remain closed (i.e., a predetermined break period). The operator that the hosemay not be used for this predetermined break period and the operator may take a break/rest during this time. Thus, the algorithm executed by the controllermaintains closure of the valvefor the predetermined break period (i.e., a second predetermined time period). For example, the displaymay show “3.0.0.0”, indicating that the hoseis not allowed to operate for the next 30:00 minutes. Once the controllerdetermines that the valvehas been closed for the predetermined break period, the controllerallows the valveto be opened once again such that the hose may thereafter be utilized. In addition, the displaymay depict a count down and update each second until it reaches “0.0.0.0” indicating that operation of the hoseis permitted again.

100 230 100 230 100 240 100 204 110 In some embodiments, the valve systemmay also include a transceiveroperable to permit communication between the valve systemand external systems at other (remote) locations. For example, the transceivermay enable the valve systemto communicate with a central monitoring systemat another location (e.g., emergency responders, a monitoring station, a designated official/employee/supervisor, etc.). In such embodiments, the valve systemmay communicate to the external location that a condition has occurred causing the controllerto close the valve.

100 232 100 110 204 100 230 240 100 232 In embodiments, the valve systemalso includes a global positioning system (GPS) receiveroperable to determine location of the valve system. In such embodiments, in addition to closing the valveupon detecting a condition, the controlleris operable to generate an emergency alert upon detecting such condition, and the valve systemutilizes the transceiverto send the emergency alert to first responders (e.g., located at the external location associated with the central monitoring system) along with the location of the valve system(as determined by the GPS receiver) such that emergency responders can reach to the operator location promptly for assistance.

100 100 100 100 2 In embodiments, the valve systemmay be integrated within a Supervisory Control and Data Acquisition (SCADA) system. Typical SCADA systems may track several safety and operational metrics, such as HS alarm status, lower explosive limit (LEL) alarm status, well shut-down/operational status, etc. Thus, in embodiments, the valve systemmay be in communication with the SCADA system, such that the status of the valve systemis sent to the SCADA system. In this manner, the SCADA system will also monitor the status of the valve systemas another safety metric.

226 100 226 100 100 100 The status tracked by the SCADA system may be the same as what is displayed on the display, or the status received by the SCADA system from the valve systemmay be different than what is shown on the display. For instance, a SCADA alarm can be sent to the console operator of the SCADA system if a fall was detected by the valve system, prompting the console operator to call/check-in with the user of the valve system. This allows prompt emergency action as needed, and is especially relevant in situations where a large number of the valve systemare being used.

100 100 100 100 100 100 Furthermore, it might be useful for the SCADA system to collect operational metrics of the valve system, such as the total time each valve systemwas pressurized. For instance, during testing & inspection activities within a plant where a large number of the valve systemsare being used, the total operational time for each of the valve systemsmay be a useful key performance indicator (KPI), which can be optimized. As an example, it might be noticed that operational time of the valve systemwas lower in certain activities as compared to when the valve systemwas used in other activities. After noticing this discrepancy in operational times, a closer investigation may be undertaken to determine the cause of such discrepancy and then corrective actions may be thereafter implemented to address the cause(s) of the discrepancy.

100 100 Furthermore, where multiple valve systemsare utilized and in communication with the SCADA system, the SCADA system may be utilized to aggregate and store operational data from all of the valve systems connected to the SCADA system, which may be utilized to optimize the fall detection algorithm. For example, the data received from the various valve systemsmay be utilized to train the fall detection algorithm.

100 242 242 102 100 242 100 242 204 110 204 242 100 100 100 In embodiments, the valve systemis integratable with an external device, such as a computer, a smart phone, a wearable device (e.g., smart watch, safety vest), etc. In these embodiments, the external devicemay be configured to capture data about the operator of the hose, such as their heart rate and or body motion. The valve systemmay communicate with the external devicesuch that the valve systemreceives the data captured by the external device, and such that the algorithm executed by the controllermay be designed to also evaluate such data when running its designed safety protocol. For example, the algorithm may be designed to cause closure of the valveif the controllerdetermines that the operator is having an adverse health condition (e.g., a heart attack), which may be indicated by the data received from the external device. In other examples, the valve systemreceives various types of health and/or biometric parameters from the external device for recording/logging of such health and/or biometric parameters. Such logged/recorded data may be useful in situations where medical investigations occur following an event where the operator was harmed during use of the valve system. Alternatively, or in addition thereto, the various types of health and/or biometric parameters received by the valve system(from the external device) may be utilized to train a fall detection algorithm to the extent there is a correlation between certain health data and a safety incident (such as a fall).

100 110 102 242 224 100 100 102 110 242 204 110 242 In embodiments, the valve systemis configured to allow opening of the valveonly when an authorized user is operating the hose. Here, for example, the external devicemay be a plurality of external devices that are each associated with a different user, the memoryof the valve systemmay include information indicating which of the different users is an authorized user, and the valve systemmay be further configured to only permit use of the hose(i.e., cause opening of the valve) when paired with the external deviceassociated with the authorized user. For example, the controllerwill cause the valveto be opened only upon determining that the external deviceis associated with an authorized user.

100 240 100 242 100 102 102 100 In embodiments, data gathered and evaluated by the valve systemmay be recorded or logged. For example, the central monitoring systemmay be configured to record or log data received from the valve system. Data gathered from the external device(e.g., the wearable devices) and the valve systemmay be securely logged for subsequent analysis. This comprehensive data archive can be utilized to scrutinize operator behavior patterns, identify potential risk factors concerning use of the hose, and implement necessary enhancements to ensure superior performance and safety of the hose. The logged data also poses as a valuable asset for constructing advanced predictive models/algorithms, thereby improving the aptitude of the valve systemin preempting accidents before they occur.

3 3 FIGS.A andB 204 100 110 104 102 202 202 204 illustrate example algorithms that may be executed by the controllerto detect the fall condition, according to one or more embodiments of the present disclosure. As previously mentioned, the valve systemmay be configured to close the valveupon detecting that the hose has fallen (i.e., a fall condition), to thereby prevent uncontrolled release of fluid from the outletof the hose. Detection of the fall condition is implemented using at least the sensor, however, the type and number of sensorsutilized may depend on the type of algorithm programmed into the controller.

3 FIG.A 4 FIG. 300 300 301 202 303 204 305 204 204 202 305 305 depicts a methodfor detecting the fall condition utilizing a threshold-based algorithm, according to one or more embodiments of the present disclosure. The methodbegins at, wherein the inertial data is captured by the sensor, as indicated at, after which the inertial data are communicated to the controllerto process the data through characterization, as indicated at. In embodiments, the controlleris configured to time-stamp each bit of inertial data or associate the inertial data with a time. In other embodiments, the inertial data received by the controllermay already be time-stamped, such as by the sensor. The inertial data is the input utilized by the threshold-based algorithm at. When the inertial data is fed into the threshold-based algorithm at, the threshold-based algorithm characterizes the inertial data, and the characterization includes analyzing the sensor data to extract values of relevant features, as detailed below with reference to.

302 307 204 302 302 204 307 302 204 304 The threshold-based algorithm includes several thresholds/conditionsthat must be met to determine that the fall condition has occurred, as indicated at(i.e., “Detect Fall”). Stated differently, the controllermust determine whether the relevant features identified in the data satisfy the thresholds/conditionsand, if each of the conditionsis satisfied, the controllerdetermines that a fall condition has occurred, as at. If any one of the conditionsis not met with respect to the relevant features identified in the sensor data, the threshold-based algorithm instructs the controllerthat the fall condition has not occurred, as indicated at.

302 202 202 302 302 202 204 110 302 202 202 302 302 302 302 307 302 202 302 302 302 302 302 307 302 The number of conditionsutilized by the threshold-based algorithm may or may not depend on the number of sensorsutilized. For example, where the sensorincludes just an accelerometer, the threshold-based algorithm may include just one condition, wherein the conditionis whether the acceleration sensed by the sensorexceeds a minimum value that would be indicative of the fall condition and, if so, the controllercauses the valveto close. However, the threshold-based algorithm may incorporate more than one conditionfor each sensor. For example, where the sensor includes just the accelerometer, the threshold-based algorithm may check whether the value of the relevant feature in the sensor data is below a certain threshold, whether the value of another feature in the sensor data is above a certain threshold, whether a timer period associated with a feature of the sensor data is exceeds a certain threshold, etc. In yet another example where the sensorincludes an accelerometer and a gyroscope, the threshold-based algorithm may include two conditions, with the first conditionbeing satisfiable based on data received from the accelerometer and the second conditionbeing satisfiable based on data received from the gyroscope, and satisfaction of both of the conditionsindicates occurrence of the fall condition at; however, in other embodiments the sensor data obtained from each of the sensors in this example may be associated with more than one condition. Even a further example where the sensorincludes an accelerometer, a gyroscope, and a magnetometer, the threshold-based algorithm may include three conditions, with the first conditionbeing satisfiable based on data received from the accelerometer, the second conditionbeing satisfiable based on data received from the gyroscope, and the third conditionbeing satisfiable based on data received from the magnetometer, and satisfaction of all three of the conditionsindicates occurrence of the fall condition at. However, in other embodiments the sensor data obtained from each of the sensors in this example may be associated with more than one condition.

302 202 202 302 302 100 Moreover, the conditionsassociated with each sensorare not necessarily independent, which means that adding another sensormay not increase the number of conditions, but such addition may change what the conditions are. For instance, when adding a gyroscope and a magnetometer to the accelerometer, the conditionassociated with a relevant feature in the sensor data can change. For example, instead of just checking whether the value of the relevant feature in the sensor data exceeds a threshold acceleration value, the check can now become whether the value of the relevant feature exceeds the acceleration threshold and that the orientation of the valve systemhas changed in a predetermined time period leading up to measurement of the relevant feature, wherein orientation is determined based on both the gyroscope and magnetometer readings. In this example, the accelerometer and the other sensors are not used independently since the predetermined time period has to be determined from the relevant feature obtained from data received from the accelerometer.

3 FIG.B 310 300 311 202 312 204 313 204 204 202 313 313 313 314 316 depicts a methodfor detecting the fall condition using a machine learning algorithm, according to one or more embodiments of the present disclosure. The methodbegins at, where the inertial data is captured by the sensor, as indicated at, after which the inertial data are communicated to the controller, as indicated at. In embodiments, the controlleris configured to time-stamp each bit of inertial data or associate the inertial data with a time; whereas, in other embodiments, the inertial data received by the controlleris already time-stamped, such as by the sensor. The inertial data is the input utilized by the machine learning algorithm at. When the inertial data is fed into the machine learning algorithm at, the machine learning algorithm characterizes the inertial data, and the characterization includes analyzing the sensor data to extract values of relevant features. The machine learning algorithm not only extracts values from the relevant features at, but the machine learning algorithm may also attribute/assign a weight to the relevant feature, which is generally resolved at, and the machine learning algorithm may also attribute/assign a threshold value to the relevant feature, which is generally resolved at. The weight assigned to the value of a relevant feature may represent how critical that type of data is for determining a fall, for example, a higher weight is given to more important conditions/attributes.

202 100 100 100 The machine learning algorithm can be trained on a set of fall data, with the fall data being of the same/similar type of data gathered by the one or more sensors, and such training may be performed to ascertain/identify threshold values and weights utilized for determining fall conditions. The valve systemneed not store the training data, but may instead store just the weights and the threshold values that were determined during the training process. Alternatively, the training data may be saved within the valve system, and the training algorithm can be periodically run on the valve systemutilizing both the training set and historical operational data. Specifically, there will be false fall conditions detected during operation and there will be some true fall conditions detected during operation; and, if the sensor data were recorded for these true and false detected fall conditions and if such incidents were tagged as either a true fall or a false fall, then the machine learning can train on such true and false fall conditions to optimize the attribute weights and threshold value.

100 100 204 100 310 204 314 316 204 317 204 318 Another approach for continuous optimization is to perform such optimization outside of the valve system. For example, the operational data of all valve systemscan be aggregated within a SCADA system, tagged, and then utilized as a larger training set; and any new attribute weights and/or threshold values obtained via training with the larger training set may then be communicated to the controllerof any one or more of the valve systemstied into the SCADA system. The methodneed not utilize such continuous optimization, however, as the initial weights and threshold values trained into the machining learning algorithm may be sufficient. Regardless, the controllerwill weight the values of relevant features, as at, then determine occurrence of the fall condition based on whether the weighted value satisfies/meets the threshold value requirement, as at. If so, the controllermay determine that the fall condition has occurred as at; however, if not, the controllerdetermines that the fall condition has not occurred as at.

4 FIG. 4 FIG. 202 400 402 404 406 202 400 406 202 406 406 410 412 414 416 414 418 420 202 406 410 414 416 202 204 110 106 depicts example acceleration data captured by the sensor, according to an example. In particular,is a data set/graphplotting accelerationover timefor an example fall condition, and an algorithm may be designed to determine occurrence of a fall condition by comparing data captured by the sensorto certain features of the data setof the example fall condition. For example, the algorithm could check whether the readings from the sensorover a specific time period are consistent with features of the example fall condition. As shown, the example fall conditionincludes a minimum reading, which is indicative of a free fall that began at a deceleration indicated at; a maximum reading, which is indicative of an impact; a high variability of readingsdirectly after the maximum readingand ending at, which is followed by generally stable readingsfor an extended period of time. The algorithm may compare the data captured by the sensorto certain features of the example fall condition, such as the minimum readingimmediately followed by the maximum readingand the high variability of readings, and if the readings captured by the sensorwere of sufficient magnitude and lasted for similar amounts of time, the controllerexecuting such algorithm may determine that the fall condition has occurred and cause the valveto close the interior passageway.

100 400 202 412 410 414 416 418 416 420 305 202 3 FIG.A Thus, the valve systemmay utilize data, such as the data shown in the graph, when implementing algorithms that detect fall conditions. With regard to the threshold-based algorithm of, the threshold-based algorithm characterizes the inertial data received from the sensor(s)in order to extract values of relevant features, and such relevant features may include any one or more of the deceleration, the minimum reading, the maximum reading, the high variability of readings, the endingof the high variability of readings, and the generally stable readings. For example, the characterization of data, indicated at, may include analyzing the sensor'sdata to extract the values of the relevant features.

204 202 414 410 202 204 202 416 204 202 420 202 204 302 307 204 410 414 302 204 204 304 Here, the controllermay continuously monitor data received from the sensorin order to determine the maximum reading (corresponding to the maximum reading) and minimum reading (corresponding to the minimum reading) in the previous 5 second window of such data received from the sensor, the controllercontinuously checks for erratic behavior in the data received from the sensor(corresponding to the high variability of readings) following the maximum reading, and the controllercontinuously checks the data received from the sensorfor the length of the stability period (corresponding to the generally stable readings) following the erratic period if one exists. To the extent that any additional sensorsmay be included, additional analysis may be performed on the data received from such other sensors, if any, in a similar manner, depending on the sensors themselves and the type of the fall detection algorithm. Then, the threshold-based algorithm instructs the controllerto compare the value of the relevant features/readings with the threshold values, as indicated at, and determines atthat a fall condition has occurred if all the conditions are satisfied. For example, the controllercould compare sensor data corresponding with the minimum reading and verify that its value is less than or equal to a threshold value of the minimum reading, and compare sensor data corresponding with the maximum reading to verify that its value is greater than or equal to a threshold value of the maximum reading, and if both of those conditions (i.e., the conditions) are satisfied, the controllermay determine that the fall condition has occurred. But, with the threshold-based algorithm, if one of the conditions is not satisfied/met, the controllerwill no determine occurrence of the fall condition, as shown at.

3 FIG.B 204 100 204 416 316 204 317 204 318 414 Regarding the machine learning algorithm of, the controllermay still determine occurrence of the fall condition even if the sensor data fails to satisfy one or more of the conditions. Stated differently, failure of the sensor data to satisfy all of the conditions does not necessarily lead to a rejection of a fall condition when using the machine learning algorithm. For instance, given the shape and weight of the valve system, it may be the case that sensor readings that, when characterized by the controller, approximate an erratic period (corresponding with the high variability of readings) are not associated with actual fall conditions. Therefore, the condition associated with such erratic period may be assigned a relatively lower weight than other features of the sensor data, as providing a feature with a lower weight decreases that feature's influence on the total weight, which may lead to detecting a fall if other conditions/attributes are met. For example, features such as the maximum reading and the minimum reading preceding the maximum reading may be more indicative of an actual fall condition and therefore assigned relatively higher weights, and the weighted value of the erratic period added to the weighted value of the minimum reading and/or weighted value of the maximum value to calculate the total weight, and if the total weight satisfies the threshold, at, the controllermay determine occurrence of the fall condition, at; whereas, if the total weight does not satisfy the threshold, the controllerdoes not determine occurrence of the fall condition, at. Also, high weights may be assigned to certain features that tend to be indicative of the fall condition, such as the maximum reading, which may help guarantee that they satisfy the threshold and, moreover, assigning such high weights to certain features may result in such features single handedly causing the total weight to become below the threshold, leading to rejecting the occurrence of a fall condition.

110 102 As previously mentioned, the algorithm utilized to control operation of the valvemay also be designed to ensure operation of the hoseonly when the ambient temperature is safe and to inhibit operation upon detecting the unsafe temperature condition.

5 FIG. 500 202 204 110 202 100 202 depicts an example algorithmfor controlling operation based on the unsafe temperature condition, according to an example. In this example, the sensorincludes (at least) a temperature sensor and a humidity sensor, and the controller, when executing such algorithm, may utilize data captured by the temperature and humidity sensors as inputs to the algorithm for controlling operation of the valve. Utilizing the sensorthat incorporates a temperature sensor and humidity sensor may be beneficial in embodiments where the valve systemis controlled in part via heat index calculations, as detailed below, but in other embodiments, the humidity sensor may be omitted such that the sensormay include just a temperature sensor.

204 202 204 204 110 102 204 110 106 202 204 110 106 202 The control algorithm may incorporate a Heat Index (“HI”) calculation, which is a measure that combines humidity and temperature measurements to assess how the ambient temperature will feel to an operator or worker. In particular, the controllermay be configured to calculate the HI based on data received from the sensor. If, for example, the controllerexecuting the algorithm determines that the calculated HI exceeds a certain threshold temperature, the controlleremits a signal to close the valve, such that the operator is unable to continue operating the hose. The threshold temperature may represent a maximum safe temperature within which an operator may work. For example, the Occupational Safety and Health Administration (OSHA) of the U.S. government considers it dangerous for operators to work in ambient environments having HI exceeding 103° Fahrenheit (“°F”) and, therefore, the HI threshold temperature may be set at 103° F. Thus, in this example, the algorithm incorporates a single threshold temperature, wherein the controllercauses the valveto close the interior passagewaywhen the sensorsdetect temperatures exceeding the threshold temperature. The controllercauses the valveto open the interior passagewaywhen the sensorsdetect that the temperature has fallen below the threshold temperature, indicating a safe working environment.

5 FIG. 500 110 110 110 110 502 504 204 110 504 504 502 110 In the example depicted in, the algorithmincorporates a plurality of threshold temperatures for controlling operation of the valve. By using different threshold temperatures for controlling when to close the valveand when to re-open the valve, it is possible to inhibit minor temperature fluctuations from repeatedly opening and closing the valvein quick succession. In the illustrated example, a dangerous temperature thresholdis set at 103° F. and a shutdown temperature thresholdis set at 107° F. The controllermay be configured to cause closure of the valveupon detecting temperatures at or exceeding the shutdown temperature threshold. By setting the shutdown temperature thresholdat a higher temperature than the dangerous temperature threshold, the algorithm is able to account for measurement error, and ensure closure of the valveonly occurs for temperature related reasons when the ambient HI is actually at a dangerous level and not induced by measurement error.

500 506 502 204 110 506 506 102 204 110 110 The algorithmfurther incorporates a resume operation thresholdthat is below the dangerous temperature threshold. The controllermay be programmed to inhibit reopening of the valveuntil temperatures at or below the resume operation thresholdare detected. Here, the resume operation thresholdis set at 95° F. In this manner, whether the hoseis allowed to operate in an ambient environment exhibiting a HI of 103° F. depends on whether this HI is reached from lower temperature, in which case the controllerwill permit opening of the valve, or from temperatures at or above 107 F° where the opening of the valveis not allowed.

500 202 202 202 202 224 500 204 110 106 204 202 506 In examples, the algorithmmay cause the sensorto continuously take temperature and humidity readings, cause the controllerto continuously re-calculate the HI using the newly captured data from the sensor, and cause the controllerto compare the re-calculated HI values to the various threshold values stored in the memory. Thus, the algorithm, when executed by the controller, is configured to cause the valveto maintain closure of the interior pathwayuntil the heat index value calculated by the controller(using data captured by the sensor) is equal to or less than the resume operation threshold temperature.

6 FIG. 600 204 100 110 102 102 100 204 202 204 102 204 110 102 illustrates another example algorithmthat may be executed by the controllerto detect the time interval condition, according to one or more additional embodiments of the present disclosure. As previously mentioned, the valve systemmay be configured to close the valveupon detecting that the operator has continuously used the hosefor the predetermined time period, to thereby prevent operator fatigue and influence operators to periodically take breaks from work. To detect when the hoseis being used and for how long, the valve systemmay be equipped with a timer (e.g., the controllermay include a timer, such as a programming variable that updates once an update request is required by the algorithm) and the sensormay include (at least) a pressure sensor. The controllermay analyze data captured by the pressure sensor and compare the captured pressure data to a threshold pressure value in order to determine when the hoseis being operated and to determine a start time for such operation. The controllermay cause closure of the valveupon determining that the hosehas been operated for at least the predetermined time period.

600 100 602 600 604 102 604 600 102 600 606 604 600 202 600 608 102 102 608 In the illustrated example, the algorithmis designed to impose a 30 minute break for every 5 hours that the valve systemis operated (i.e., 5 hours is the predetermined time period threshold). In this example, each reading from the pressure sensor triggers the algorithm as shown at, and then the algorithmchecks whether the pressure reading exceeds a certain threshold pressure, as shown at. This threshold pressure is indicative of the pressure of the fluid circulating through the hoseduring normal operation and thus may depend on the specific application. If, at, the algorithmdetermines that the pressure detected does not exceed the threshold pressure (i.e., which would indicate that the hoseis not pressurized), the algorithmdoes not proceed further and terminates, as indicated at. If, at, the algorithmdetermines that the pressure detected by the sensorexceeds the threshold pressure, the algorithmproceeds by calculating the difference between the “Current Time” and “P Time” (i.e., Current Time minus P Time), as indicated at, where P Time is the last recorded date/time where the pressure exceeded the threshold. For instance, if the hosewas operated on 1 Jan. 2023 at 6:20 AM, and then the hosewas operated again at 6:33 AM on the same day, P Time would be 6:20 AM on 1 Jan. 2023, whereas the Current Time is 6:33 AM on 1 Jan. 2023, and the difference between the Current Time and P Time calculated atwould be 13 minutes.

600 600 608 610 600 612 614 610 600 608 600 616 Since the goal of the algorithmis to force the operator to take a 30 break for every 5 hours of work, the algorithmdetermines whether the difference calculated atis equal to or greater than 30 minutes, at. If so, the algorithmresets the timer as shown atand P Time is updated as shown at. However, if atthe algorithmdetermines that the difference calculated atis less than 30 minutes, the algorithmincrements the timer, as shown at.

618 600 620 110 600 618 204 110 622 110 624 Then, at, the algorithmdetermines whether the total value of the timer exceeds the predetermined time period (e.g., 5 hours or some other maximum time period threshold). If not, the algorithm updates P Time, as shown at, and the valveis allowed to remain open. However, if the algorithmdetermines atthat the total value of the timer exceeds the predetermined time period, the controllercauses the valveto close, as shown at, for a duration of time (e.g., for 30 minutes) to impose a break on the operator and mitigate chances of fatigue due to overwork. Also, when closing the valve, the algorithm will update P Time, as shown at.

600 100 100 100 100 100 600 100 100 102 600 610 612 614 600 600 616 The algorithmmay be utilized in a variety of utilization scenarios, such as where the operator, intending to remove the coating on a pipeline via the valve system, moves to the pipeline location and starts a test blasting on the ground using the valve system. However, the blast pressure may need further changes, leading to multiple pressurization & de-pressurization cycles of the valve system. Furthermore, during the blasting activity, the operator may need to change their position (e.g. drop below the pipeline) or may need changes to the scaffolding system on which they are standing when using the valve system. This process includes a lot of periods where the operator is working, but where the valve systemis not pressurized. The algorithmcaptures the overall working time, which includes both the time that the valve systemis pressurized as well as some additional time with when the valve systemis not pressurized; and this means that certain time periods between pressurization events is considered part of the overall working time, unless amount of time between pressurization events exceeded a certain amount of time (e.g., the break period of 30 minutes), meaning the operator did not pressurize the hosefor 30 minutes straight or more, in which case it is assumed that the operator took a break and then the timer may be restarted. Thus, the algorithmchecks (at) whether the operator took a suitably long break and, if so, the timer is restarted (at) and the working time is re-initialized (at). However, if it is determined via the algorithmthat the operator did not take a break, the algorithmproceeds to step.

600 102 102 600 612 614 102 616 620 102 102 600 600 600 100 604 606 As mentioned, the timer may be a programming variable that updates upon request by the algorithm. Accordingly, in a scenario where the operator started the work period by pressurizing the hose at 7:00 AM, because the hosewas not being utilized since the day before (i.e., the hosewasn't operated at least in the period between 6:30 AM and 7:00 AM such that the difference is greater than 30 minutes), the algorithminitially proceeds via stepsand, where the timer is set to a timer value of 0:00 and the period time, labeled as “P Time”, is set to 7:00 AM. Following the initial values set, assume the operator continued blasting and pressurizing the hoseuntil 7:10 AM. During this time, all pressure readings were being passed through stepto step, as further described below. Once the operator stops blasting/pressurizing the hoseat 7:10 AM, the timer value will be 0:10 and “P Time” will be 7:10 AM. If, for example, the operator moved around until 7:15 AM and then started pressurizing the hose, both the timer value and the “P Time” will remain at 0:10 and 7:10 AM, respectively, because the algorithmcauses the timer value and “P Time” to update their values once the algorithmrequests an update. However, the algorithmdoes not operate when the valve systemis not pressurized, as indicated at stepsto.

102 102 604 600 608 600 616 616 0 5 616 620 620 620 Pressurization of the hosewill cause the pressure in the hoseto exceed a threshold pressure (at), and immediately thereafter at 7:15 AM the algorithmwould operate as follows. At, the difference value will be 0:05, which is calculated as the difference between the current time (7:15) and the previous “P Time” (7:10). Because this difference is not greater than the break time (i.e., 30 minutes), the algorithmmoves to step. At, the timer still has a value of 0:10; however, in this step, the timer value (0:10) is to be incremented by the difference value (:). Therefore, at the end of stepin this example, the timer value becomes 0:15 and, because this timer value is not greater than 5 hours, the algorithm proceeds to step. At, “P Time” is still 7:10 initially, but it gets updated via stepto 7:15.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, for example, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “contains”, “containing”, “includes”, “including,” “comprises”, and/or “comprising,” and variations thereof, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Terms of orientation used herein are merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to an operator or user. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third, etc.) is for distinction and not counting. For example, the use of “third” does not imply there must be a corresponding “first” or “second.” Also, if used herein, the terms “coupled” or “coupled to” or “connected” or “connected to” or “attached” or “attached to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such.

While the disclosure has described several exemplary embodiments, it will be understood by those skilled in the art that various changes can be made, and equivalents can be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation, or material to embodiments of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, or to the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative.